NOBODY READS MANUALS

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1 Compressors for Dummies (Updated ) NOBODY READS MANUALS Make this one the exception you will be glad you did This book is frequently updated - If you would like free updates Just jstark@starkindustries.com & put CFD Update in the subject line Questions, comments, suggestions & tech support - jstark@starkindustries.com Using the Tables of Content in PDF Format This book is generic in nature and applies to most high pressure breathing air compressors. Please notice the book has been completely re-formatted in chapters to facilitate finding your desired topic. Simply look at the chapter of your choice then click the page you want and you are there. At the top of every page there is a return link back to the contents page. Also there are links on some pages that will take you to another page with related topics or pictures. These pages may also have a link back to the page you were on. Otherwise go back to contents and click back to the page you were on. The key word search works very well as an INDEX see p. 130 for How To instructions, also you can change your PDF setting to 200% or more to zoom in on any part of the book. There is also an alphabetical index beginning on p. &

2 Loss Prevention & Warranty Activation 2 SCUBA diving, Fire Fighting, and the use of SCBA in an industrial setting are all activities that involve a high degree of risk. Proper operational and safety considerations can go a long way in the prevention of accidents. Some of the matters that you should consider (this is not intended to be an all-inclusive list) in a loss prevention program are: 1. Air tests It is prudent for any one supplying breathing air to perform frequent air testing by a reputable lab. See Dew Point p The higher the test frequency, the more assured you could be that the air is safe for human consumption. In the event of a failed test, take corrective measures immediately and re-test. See Air Testing p. 88, Oily Air p Record keeping This is such an important issue that a logbook template is on p. 42 with a How To introductory page on p. 41. Your hour meter is your most important tool p. 25. It is the owner s responsibility to make sure that entries are made regularly, accurately, and frequently. The technician s initials or signature allows responsibility to be pinpointed. Notations of preventative maintenance, air tests, and purifier cartridge changes prove that everything humanly possible is being done to ensure the highest quality breathing air is being produced. See p. 41 Log Book Check List 3. Operator qualification It should be mandatory that only trained operators be allowed to run and maintain the compressor. Periodic in service re-training is also a good idea, plus it maintains the professionalism of the entire operation for all to see. Stark Industries offers in depth training anywhere in the world. 4. Cleanliness p. 45 A compressor room that is well ventilated, roomy, neat, and as clean as hospital operating room presents an image more powerful than a million well phrased words. Many shops use the compressor room for storage of the most bizarre array of junk you can imagine. I have even seen wet suits lying on some compressors in dive shops. This type of activity creates the potential for accidents and is a clear indication of sloppy operating procedures. 5. Precautions against toxic gases Positive steps should be taken to ensure that the presence of paints, solvents, sprays, HTH, chlorine, pool chemicals, gas-fired heaters, engine exhaust, or other potential sources of carbon monoxide or other dangerous gases is not possible while the compressor is running. An operating procedure that includes these precautions should be placed conspicuously near the compressor controls. Competent, alert, conscientious operators are mandatory. 6. Signs In addition to No Smoking signs in the compressor room, additional signs should be placed where potential danger exists. For instance No Parking, No Painting, or No Whatever signs posted in or around the compressor room where appropriate. 7. Compressor condition A properly functioning compressor will not produce carbon monoxide. Make sure it stays clean and in top condition. Changes in inter-stage pressures are usually a precursor to a valve or cylinder malfunction. See the Log Book Check List p. 41. Keep the wiring neat and the electrical enclosure closed with appropriate warning signs attached. Also see p ventilation 8. Safety consultant - Discuss these and other issues with your safety officer in order to achieve an environment that is most likely to prevent accidents. My signature below acknowledges my commitment to read this manual in its entirety. A signed copy of this page must be submitted to Stark Industries in order to activate my warranty. I realize that a thorough knowledge of this equipment is my best assurance of achieving long-term reliable service and avoiding accidents. Log book maintenance is also a condition for keeping the warranty in effect. Customer Signature Printed Name Date

3 Chapter 1 Compressors Table of Contents 3 JUST CLICK the page you want Basic theory Page High pressure compressors (Basic Theory) 7 Four stage compressor arrangement 8 Compressor cross sections 9 Recompression Altitude Vs. compressor performance 16 Carbon 20 Engine Vs. Electric compressors Quality assurance test certificate (QA-2) 134 Components Component pictures Intake filter 24 Hour meter 25 Pressure switches Recommended spares 28 System components 29 Relief valves Fittings and tubing basics 162 Diagnostic & Trouble Shooting Procedures Compressor diagnostic 31 Troubleshooting 32 Water in the crank case Oil leaks 54 Installation & Start-Up Procedures Installation of compressor 36 Startup procedures Operating procedures 39 Log book check list Log book template 42 Remote air intake Ventilation 44 Maintenance procedures Cleanliness 45 Compressor maintenance Drive belts 47 Infrequent operation & start up Lube change procedure 49 Murder by neglect (compressor) Vibration & Loose parts 51 Test procedures Air flow check procedure 52 Blow-by test 53 Leak testing 54

4 Chapter 2 Purification Table of Contents JUST CLICK the page you want Basic Theory Preface 55 Purifier Basics - Theory & understanding the process 56 Cartridge Change theory 58 Adsorption Vs. Absorption Air path 60 Purifier cartridge & chamber base relationship 61 Air venting purifier chambers 62 Carbon dioxide Carbon monoxide 64 Contact time (dwell time) 65 Effect of temperature on cartridge life 66 Purifier cartridge life Pressure drop across purification 68 Purifier fires 69 Trap discharge 70 Purifier mass transfer zone Purifier picture (APA-58 - two chamber system) 147 Oily Air 160 Components Components Back pressure valve (BPV) 72 APA-58 purifier diagram (picture p. 147) 73 After coolers 74 Poor man s refrigerated after cooler 75 Water cooled after cooler Trap cross section drawing 77 Cartridge ruptures 78 Trap failures 79 Purifier systems for high flow compressors More on high flow purifiers 161 Purifier fittings 162 Corrosion (purifier base) 157 Maintenance Procedures Cartridge change procedures (changing a cartridge) Cartridge plug removal 81 Cartridge storage plus Corrosion 82 Priority valve (BPV) Monitoring Cartridge monitoring 84 Purifier O ring installation 85 Murder by Neglect (Purification) 86 Testing NFPA air quality standards Air test procedures 88 Dew point (moisture content of air) and purifier troubleshooting 154 4

5 Table of Contents Chapter 3 Ancillary Equipment JUST CLICK the page you want 5 Condensate Drain Systems Auto vs. Manual 89 Drain separator silencer Manual drains 91 Stark MK-IV automatic condensate drain valve (ADV) Stark MK-VII auto drain system (ADS) 94 Test procedure 98 Fill Stations & Storage Systems Basic fill panel 99 Caribbean fill manifold Tank filling & temperature 103 Storage system & Cascade filling procedure 105 & 106 Tank filling chart Tank cleaning 156 Monitors Carbon Monoxide, CO Carbon Dioxide, CO 2 Oxygen, O 2 Moisture, H 2 O Chapter 4 Electrical Related Topics (+ more in the Index) Electric Connections 109 Low oil pressure switch 110 Motor volts & amps 111 Motor speed Nominal motor amperage 113 Wire Amperage Ratings 114 Pressure Switches 115 Wiring arrangements 3 phase motors Three phase vs. single phase Understanding Electricity 118 Diagram 220 volt operation 120 Diagram 480 volt operation 122

6 Appendix Table of Contents 6 JUST CLICK the page you want Conversion table for moisture 123 Definitions 124 Frequently asked questions (or test) 125 FAQ answers Glossary of terms & Abbreviations 129 Key word search instructions 130 Pressure conversion table 131 Pressure gauges Dry Vs. Liquid Quality assurance test certificate (QA-2) 134 Torque values SAE fasteners (foot pounds) 135 Torque values Metric fasteners (foot pounds) 136 Toxic chemicals Tubing pressure ratings 138 Tube fitting types, pictures 140 Weights of materials Diesel Problems 143 Compressor Life 144 Mass Transfer Zone Splash versus Pressure Lubrication 146 Purifier picture 147 Relief valves Motor AMPS NEC chart 149 Belt length calculator 150 Pipe & tubing dimensions 151 Motor Shaft and Frame sizes Torque values SAE fasteners (Inch Pounds) 153 Dew Point (Moisture content) 154 Excerpt - University of Washington Environmental Health Laboratory & PDF 155 Contaminated tank cleaning 156 Purifier base stress corrosion Furnas overload relay Heater values 158 Oily Air 160 More on high flow purifiers Fittings & plumbing basics 162 O ring Basics 163 O ring Material Charts 164 & index 6